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Cogeneration, also known as Combined Heat and Power (CHP), is the on-site production of multiple types of energy usually electricity, heat and/or cooling from a single source of fuel. Cogeneration often replaces the traditional methods of acquiring energy, such as purchasing electricity from the power grid and separately burning natural gas or oil in a furnace to produce heat or steam. While the traditional method of purchasing electric energy from a utility is convenient, it is very inefficient and wastes almost 75 percent of the energy in the original fuel due to production and transportation losses. (See Figure 1)
Fuel 100% >30%
On-site cogeneration systems convert 70 percent to 90 percent of the energy in the fuel that is burned into useful electricity or heat. Depending on the application, the integration of power and heating/cooling production into one on-site cogeneration system can often produce savings of up to 35 percent on total energy expenditures. If your facility is a big energy user, those kinds of savings can pay for installing a cogeneration system in as little as two to three years for some applications.
Fuel in 100%
60% waste
810% waste
4042%
Figure 1 - Todays grid system of central power plants and transmission lines wastes much of the energy in the original fuel.
Figure 2 - CHP plants operate at twice the average efficiency of the U.S. power system.
Today, however, advances in lean-burn gas reciprocating engine technology, heat exchangers and digital system controls make cogeneration both practical and economical for applications as small as 300 kW. This is causing many more types of facilities large and small to take a fresh look at cogeneration as a way to improve energy efficiency, cut greenhouse gas emissions and reduce costs. A cogeneration system normally consists of a prime mover turning an alternator to produce electricity, and a waste heat recovery system to capture heat from the exhaust and engine-cooling water jacket. The prime mover can be a lean-burn natural gas reciprocating engine, diesel reciprocating engine, gas turbine, microturbine or fuel cell. While the ratio of heat to electricity production differs between reciprocating engine systems and gas turbine systems, as much as 90 percent of the energy in the original fuel is put to productive use in a cogeneration system. (See prime mover options below.) Less than 10 percent of the electricity used in the United States today is produced by cogeneration systems, but the Department of Energy (DOE) has established a goal of having cogeneration comprise 20 percent of generation capacity by 2030. The European Union generates 11 percent of its electricity using cogeneration. Denmark (43 percent) followed by Latvia (41 percent) are already well ahead of the curve.
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5. Are local electric rates high in relation to the local cost and availability of natural gas? Known as the sparkspread, the greater the differential between the price of electricity and the price of natural gas (on an equivalent Btu basis), the greater the likelihood that a cogeneration system will provide substantial savings. 6. Is your physical site suitable for the installation of a cogeneration system? Youll need sufficient space to house the generators, heat-exchangers, switchgear and control systems. Small systems can be located outdoors in special packaged enclosures; however, larger systems may need their own room or a freestanding building. There also needs to be a supply of natural gas to the facility. Environmental factors should also be considered, such as state and local air-quality standards and noise ordinances. 7. Is reliability of electric service a major economic concern? For many commercial and industrial facilities, a power outage can be very costly due to lost productivity or revenue. In many areas, utilities are incapable of delivering the kind of reliability that is necessary. In contrast, on-site cogeneration systems when designed with sufficient redundancy, standby generators and uninterruptible power supply (UPS) systems offer significantly better reliability than local utilities. On-site power systems are less vulnerable to storm damage and transformer or transmission line failures, and, with proper maintenance, will offer decades of reliable operation.
This 2 MW lean-burn gas engine generator set supplies heat, steam and power for a Danish poultry farm, and heat for a nearby village.
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A cost analysis is best done with the help of a representative from a system manufacturer such as Cummins Power Generation or a consulting engineer familiar with cogeneration systems. However, the factors that go into the calculation are: 1) electricity costs per kWh; 2) electricity demand charges;
3) cost of natural gas; 4) number of anticipated hours of operation per year; 5) utilization of recovered heat; and 6) installed cost of the cogeneration system. This information is used to estimate the annual savings and payback for your facility. For a sample payback analysis, read below:
You can see from the figures that an on-site generator that produces both electricity and thermal energy can cut total energy expenditures and carbon dioxide emissions by a significant amount. In this example, the cogeneration system will pay for itself in little more than two years.
25000 20000 15000 10000 5000 YEAR 10 0 YEAR 1 YEAR 2 YEAR 3 YEAR 4 YEAR 5 YEAR 6 YEAR 7 YEAR 8 YEAR 9
CO2 Savings
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the Leadership in Energy and Environmental Design (LEED) standards developed by the U.S. Green Building Council include an LEED-NC (New Construction) certification with a requirement for two energy optimization credits; facilities can earn one of these credits by installing a cogeneration system. To help facility managers calculate the amount of reduction in greenhouse gases and fuel that can be achieved with a cogeneration system, the U.S. Environmental Protection Agency (EPA) has created an online tool. This interactive tool can help facility managers or consulting engineers evaluate the environmental and energy-saving benefits of cogeneration. This calculator can be found at www.epa.gov/chp/basic/calculator.html
These two 2MW lean-burn gas fueled generator sets are in operation at a cogeneration plant that provides base load power and hot water for an Australian hospital.
Conclusion
Cogeneration systems that produce both electricity and heat/cooling from the same fuel can offer energy savings of up to 35 percent for a wide range of facilities, while at the same time contributing to building sustainability and protecting the environment. The potential for cost savings in energy expenditures is usually the motivating reason to consider cogeneration, but building sustainability and regional certifications are becoming reasons on their own to investigate the potential benefits of cogeneration for your facility.
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Information resources
For additional environmental and cogeneration information, visit the web sites listed here: The Association of Energy Engineers, www.aeecenter.org Buildings Cooling, Heating, and Power (BCHP) Initiative, www.chpcentermw.org Electric Power Research Institute (EPRI), www.epri.com EPA, www.epa.gov/chp/basic/calculator.html TA Luft, http://www.bmu.de/en/topics/air-mobility noise/air-pollution-control/ta-luft/
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